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Valve Actuation News from Rotork

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www.rotork.comwww.rotork.com

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Double the test,double the orders

As reported in the last Rotalk

issue, the successful life testing of

a Rotork IQ electric actuator

simulating over 50 years of

operation by performing 20,000

punishing cycles within a three

month time frame resulted in

the award of an order in the USA

for over 130 actuators for the

expansion of the Explorer

Pipeline, delivering petroleum

products from the Gulf of Mexico

as far north as Chicago.

Tom Matthews, Rotorks sales

manager in Houston, has since

reported that a subsequent

request to perform an identical

test with the same sized 24inch

Class 600 ball valve from another

manufacturer was also

successfully completed using

exactly the same IQ70 actuator which has therefore now

completed over 40,000 cycles in

its busy life!

At the same time, Tom has also

received a second order for the

pipeline terminal stage of the

project, involving another 40

IQ actuators, complete with a

Pakscan IIE master station to

provide dedicated two-wire

control and monitoring.

Nigerian tank

farm successRotork Retrofit in the UK has

overcome fierce competition from

European actuator manufacturers

to win an order for the

modernisation of over 100

motorised valves on the Nigerian

Agip Oil Companys Brass

Terminal. Again, IQ intelligent

More orders atgiant refineryThe giant Reliance oil refinery at

Jamnagar on the west coast of

India is the destination for more

IQ actuators, ordered for a new

pipeline distribution network.

This latest order reinforces Rotorks

success at Jamnagar, where more

than 2500 IQ actuators were

installed during construction of the

refinery, tank farm and powerstation during the late 1990s.

Occupying a site as large as

Central London, the Reliance oil

refinery is amongst the worlds

largest. In many plant areas Rotork

Pakscan control systems have also

been installed, dramatically

reducing the cabling costs of

linking large numbers of valve

actuators over long distances to

Foxboro Intelligent Automation

DCS equipment in centralised

control rooms.

The latest orders involve over 100

IQ electric actuators to operate

valves manufactured by Tyco

Valves and Controls Ltd. The

distribution network will facilitate

the movement of the multi-product

petrochemicals manufactured by

the refinery to industrial and

commercial areas on the Indian

subcontinent.

actuators have won the day,

together with two Pakscan IIE

master station systems, ordered

by the Nigerian contractor

Sudelletra.

Rotalk - Issue 21 2

For further information on Rotalk articles and features contact Katrina Swinson at Rotork Bath . . . .

ContractNews

Get the brochure:Contact your local

Rotork representative or

visit www.rotork.com

A new range of compact,

direct drive quarter-turn

electric actuators for the

inexpensive motorisation of

small ball and butterfly valves,

dampers and louvres is now

available from Rotork.

The new units, designated ROM

and RBM, complement Rotorks

established ranges by extending

the scope for directly mounted

electric actuation down to valves

typically as small as 12mm (1/2).

Applications include heating,

ventilating and air conditioningequipment, chemical processing

plant and the food, dairy and

drinks industries.

All models feature a watertight

enclosure conforming to IP67

(NEMA 4/4X), equipped with

continuous local position

indication as standard. A

comprehensive list of options

can be specified, including

adjustable torque switches,

remote position limit switches,

current position transmitter,

potentiometer, modulating

controller and local control

switches.

Available for AC single and three

phase or DC operating voltages,

all ROM and RBM actuators

feature rugged, self-locking andpermanently lubricated gear

trains for accurate and

repeatable performance, offering

long term reliability under every

day working conditions.

Electric actuatorsfor small valves

With over 20,000 I/O points, each

In-Vision is suitable for automatedplants containing up to 480

Pakscan controlled valves. Even

larger systems can be controlled by

using multiple applications spread

across several PCs. In-Vision

enables a totally customised, full-

colour visual display of the site to be

used to monitor and operate the

plant using information collected on

the Pakscan two-wire control bus.

Customisation options include the

ability to include photographic

In-Vision bringsPC based supervisorycontrol into the

21st centuryIn-Vision is Rotorks new, user friendlysupervisory control and data acquisition

software package designed for use with

Rotorks Pakscan two-wire control system.

Developed from the popular, industry proven

Pakvision package, In-Vision runs under

Windows 9X, NT or W2000 to introduce many

new visual features and operational benefits.

images on the animated screen

overviews and close-ups thatdisplay general plant conditions.

Detailed examinations of chosen

plant areas can be performed using

enlargements featuring coloured

animations to highlight alarms or

areas requiring attention. To further

facilitate plant operation, every

In-Vision system incorporates

multiple windows providing status

and alarm information and showing

the condition of every actuator and

master station on the Pakscan

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Telephone (+44)(0)1225 733200 or email katrina.swinson@rotork.co.uk

system. Audible warnings and action

confirmation dialogue boxes can be

included to enhance safety where

plant controls are critical.

Historical event and alarm data is

automatically logged by In-Vision

and may be viewed, printed or

exported for further analysis on

spreadsheets or similar applications.

When used with Rotork IQ

actuators, additional displays may

be incorporated to show a graph of

the torque values at various

positions in the valve stroke as the

valve opens and closes.

This information may be used in

combination with the historical data

to maximise plant availability and

accurately prepare preventative

In-Vision enables the user to look at detailed plant and zone overviews (top), alarmscreens (left), system status screens (above) and, with IQ actuators, torque profile

panels for individual valves (above, right).

Actuation

News

maintenance schedules.

The In-Vision MD version enables

this information to be used as an

economical maintenance and

diagnostics utility without the

customised display and control

abilities inherent in the full In-Vision

software package.

All that is needed to use In-Vision

which is supplied on a CD-ROM as

a run-time version as standard is a

100Mhz or above Pentium class PC

with 128 MB Ram and 200MB free

hard disk space. Alternatively, the

Rotork TSI touch screen interface

available in a weatherproof

enclosure for installation within the

plant itself can be used.

The worlds first full sized plant to

use the Regenesys regenerative fuel

cell technology is nearing

completion in the UK on a site

adjacent to the 680 megawatt gas

fired Innogy Little Barford combined

cycle power station.The energy storage system,

developed by Regenesys

Technologies Ltd, a subsidiary of

Innogy plc, uses regenerative fuel

cells to convert electrical energy to

stored chemical energy. Two

electrolytes are pumped through the

fuel cells in individual circuits

separated by an ion exchange

membrane. When storing energy,

the electrolytes convert to a charged

state and can be discharged to

release energy. This cycle can be

repeated as required for the duty of

the plant.

The plant will be operated from a

central control room, using a

Foundation Fieldbus open control

system to communicate with an

Allen Bradley PLC. In addition to

Foundation Fieldbus connectivity,

Rotork actuatesrevolutionarypower industry

storage plant

the Rotork actuators are

independently linked to an ICS

Triplex ESD (Emergency Shutdown)

system.

Roughly the size of a typical DIY

store, the Little Barford plant will

have a 15MW output and be able tostore 120MWh of electricity. The

plant has been designed to meet

the National Grid Companys

requirements for Black Start

provision at the Little Barford power

station, supplying enough power to

restart power generation in the

event of network interruption.

The plant will also supply electricity

to the National Grid at times of peak

demand, having been charged at

off-peak periods. The technology is

very flexible and can be installed

virtually anywhere on a power

system. As Antony Price, Innogy

Technology Ventures marketing

manager explains: This is a very

exciting technology that could

change the way power systems

around the world are planned and

operated in the future.

a very excitingtechnology thatcould changethe way powersystems aroundthe world areplanned and

operated

a very excitingtechnology thatcould changethe way powersystems aroundthe world areplanned and

operated

Rotork IQ intelligent electric valve actuators are used in a

revolutionary energy storage plant a giant battery which, the

designers say, could change the face of the power industry.

Innogy project engineer Abid Sayeed with a Rotork IQ12 actuator operating a 600mm

isolating butterfly valve on the electrolyte pipework at Little Barford.

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For further information on Rotalk articles and features contact Katrina Swinson at Rotork Bath . . . .

Rotork IQ intelligent electric valve

actuators are being installed on

an oil industry development

scheme situated in one of the

coldest and most exposed

environments in the world.

Situated within the Arctic Circle on

the northern coastal slope of Alaska,

Borealis and Meltwater are new oil

fields being developed to offset

declining production from the

adjacent Prudhoe Bay field.

The Rotork actuators are installed onprefabricated, skid mounted plant

sections, known as pads, that are

specially designed to operate in

harsh sub-zero temperature

conditions and shipped to site as a

series of modules. In the Arctic

environment the user-friendly virtues

of Rotorks non-intrusive

commissioning and interrogation

technologies are particularly

appreciated, eliminating the need to

remove electrical covers or perform

any mechanical adjustments in the

freezing conditions.

Rotork actuators operate high

pressure ball, choke, globe and plug

valves on the two sites. At the

Borealis site, which is operated by

BP, the inclusion of a Rotork

Pakscan two-wire control and

supervision system has been very

favourably received. Being the first

Pakscan installation on the Alaskan

northern slope, it has particularly

impressed its operators with itsdiagnostic abilities. At Meltwater,

operated by Phillips 66, Modbus

and Extended Modbus protocols

are used for actuator control in the

majority of cases, linked to a

Pakscan system in one area. In

total, almost 200 IQ actuators have

been installed at the two sites

virtually all fitted with Exeeco

gearboxes together with a number

of Rotork Fluid System P range

pneumatic actuators.

Contrasting environmentson both sides of the world

Rotork actuators in Arctic

Circle oil developments

Rotork electric valve actuators

have been specified during a

modernisation project at an

important hydro-electric

generating plant serving the

state of Queensland in

North East Australia.

and Australian tropicalrainforest power plantupgrade

and Australian tropicalrainforest power plantupgrade

Rotork actuators in Arctic

Circle oil developments

Rotork Australia at Brisbane

supplied 70 AQ range IP68

watertight quarter-turn electric

actuators to operate ball valves

installed at the Kareeya Hydro on

the Tully River as part of a project to

automate the hydraulic operating

system on the main turbine feeder

valves. Situated in an area of

tropical rainforest in Northern

Queensland, the Kareeya Hydro

which takes its name from the

Aboriginal word meaning big water

has been generating electricity

since 1957. The 72 megawatt plant

plays an important role in meeting

Queenslands peak load electricity

requirements, whilst its fast response

time also contributes to the security

of the states electricity distribution

system.

The four 18 megawatt turbo

generating sets each consist of two

Pelton turbines and a generator.

Water is discharged at high velocity

through two nozzles on each

turbine, striking wheels equipped

with 22 buckets (or Pelton

runners).

The plant is operated by Stanwell

Corporation, who have used Rotork

valve actuators for a number of

years on power industry projects

throughout Queensland. The AQ

actuators for Kareeya were supplied

by Rotork to Fluid Controls of

Brisbane for attachment to the

valves.

Rotork engineer Mike Joslin demonstrates the user-friendliness of non-intrusive

IQ actuator commissioning in the freezing conditions of BP Borealis (above) andinspects one of the P range pneumatic actuators installed at the same site (top).

Below

Trevor Downing from Stanwell Corporation and Rotorks Jeff Quarrell with seven of the

newly installed AQ actuators in the generator hall at Kareeya Hydro.

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Rotalk - Issue 21 6

For further information on Rotalk articles and features contact Katrina Swinson at Rotork Bath . . . .

Traditional manual operation of

these sluices could be labour

intensive, time consuming andinefficient, as Environment Agency

M & E Flood Defence Engineer Ivan

Nicholls, who is project manager for

the automation scheme, explained:

In many cases it could take a long

time even to reach the sites, some

of which are in remote locations with

poor access. Also, especially at

night, they can be potentially

hazardous, demanding the

despatch of two men per visit for

safety reasons.

Operating the sluices manually

provides a relatively crudeadjustment, usually fully raising or

lowering the gate, which may not

always suit prevailing or subsequent

river conditions. Electric actuation,

working automatically in response to

a signal from an upstream level

sensor, introduces the ability to raise

or lower the gates in small stages at

frequent intervals, and therefore

react with far more accuracy to

changing river conditions.

However, the lack of a mains

electricity supply at some locations

was a fundamental complication

demanding a well thought outsolution before the automation

scheme could proceed. Our

enquiries revealed that Rotork

manufactured a suitable actuator for

this type of application which would

operate from a DC stored energy

Rotork at the centre ofEnvironment Agencysautomatic flood defence plan

Rotork electric valve actuators are being used throughout an innovative

river level management automation project performed by the UK

Environment Agency in the Anglian region. The ambitious project,

designed to improve flood protection in Norfolk and Suffolk, involves

automating manually operated sluice gates at river weir and bypass

channel locations throughout the area and linking them by telemetry to

centralised control rooms.

source. We were therefore able to

design an entirely self-contained

package, including all the controlelements, running from a bank of

batteries that are kept charged by

wind and/or solar power. The first

site to be modernised, on the River

Yare at Keswick Mill near Norwich,

was commissioned in 1999.

The plant installed at Keswick Mill is

typical of all the battery-powered

sites, although it is unusual in having

both solar panels and a wind turbine

generator. Four solar panels and the

turbine are used to charge the 48 volt

batteries for actuator operation, whilst

one solar panel is dedicated to the12 volt control and telemetry system.

A Milltronics ultrasonic level sensor

and controller communicates with the

actuator via a 4 to 20 milliamp

analogue gate positioning signal. In

order to maximise energy

preservation, the plant is normally

asleep, waking every hour to check

its status and make any adjustment

to the gate position before closing

down again. By making only small

adjustments at hourly intervals the

system is able to react accurately

and sympathetically to the status of

the river, without the danger of over-compensating for changes in the

water level. Real-time data from the

site is transmitted to the Environment

Agencys Anglia Region telemetry

system control rooms at

Peterborough and Brampton, and

can be accessed at other control

rooms.

Downstream from Keswick, the

multiple gate weir at Trowse is one

of the sites where the Environment

Agency has been able to install the

latest Rotork IQ intelligent electric

actuators, due to the availability of

a mains power supply. A

Mitsubishi PLC with MMI (Man

Machine Interface) touch screen

control panel is utilised for mains

powered sites, enabling the controlsystem for all actuators on the site

to be housed in the same sized

compact cabinet as the single gate

battery-powered sites. At Trowse

the introduction of the automatic

river management scheme has

been blended in with an

impressive new housing

development, built on the site of a

derelict printing works.

Further automated sites include

Hellesden Mill at Norwich on the

River Wensum and Glevering Mill

near Woodbridge on the River

Deben. At all the sites theEnvironment Agency has carried

out the civil and mechanical work

whilst the equipment design and

installation has been performed by

Dabbrooks (Eng) Ltd of Great

Yarmouth. Rotorks recent

announcement of a DC version of

the IQ intelligent actuator introduces

the ability to standardise on the IQ

for all future sites, whether mains orbattery powered. With this in mind,

Ivan has recently signed a

framework agreement with Rotork

for the Environment Agency Anglian

Region.

framework agreement to cover

valve actuation equipment, further

strengthening the close

relationship with Rotork that has

been developed over many years.

In a similar move, West of

Scotland Water (now Scottish

Water) has signed up Rotork to

supply electric actuators and

support services for new plant

and refurbishments. Thisagreement comes at a time when

an important modernisation

programme is being planned and

implemented at clean and waste

water plants throughout this area

of Scotland.

Meanwhile, Severn Trent Water

has reappointed Rotork for a

further framework period following

the expiry of its original five year

agreement, whilst Rotorks

framework agreement with

Southern Water has also been

extended for a further period.

Rotork has been amongst the

pioneers in establishing such

agreements. In addition to the

above, Rotork has frameworks

with Thames Water and South

West Water.

Continued from previous page

Ivan Nicholls demonstrates the solar

powered Rotork actuator installation at

Glevering Mill (left) and the 12volt

telemetry and control system installed at

Keswick Mill (below).

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Telephone (+44)(0)1225 733200 or email katrina.swinson@rotork.co.uk

ActuationNews

In response to customer demand for

fast, guaranteed deliveries, Rotork

Valvekits has launched this service

from a new base in Losser,

Netherlands, which is centrally

located for all northern European

countries. Complementing this

service is a new catalogue which

contains comprehensive mounting kit

drawings and an easy order guide,

supported by an innovative CAD

software based design service.

Kits to either ISO5211 or customised

dimensions are made to order or

selected from an extensive stockheld at the new European

Valvekitsexpandsinto Europe

manufacturing satellite. Quality

control is maintained as all design

work is performed at the

companys Nottingham UK

headquarters, with manufacturing

activities completed by dedicated

Rotork Valvekits personnel.

Rotork Valvekits managing director

Martin Hunt explains: This venture

will develop relationships with

existing and new customers in

Europe by providing important local

support for the entire range of

products offered by Rotork

Valvekits.

This large oil industry high pressure ball

valve and pneumatic actuator is one of a

number united by means of custom built

spool kits supplied by Rotork Valvekits.

As the UKs leading valve accessory

company,Valvekits is best known for

activities involving small and medium sized

valves,although it also has the

engineering and production resources to

manufacture adaption and spool kits for

the largest valve and fluid power actuator

combinations used in the oil, gas and

petrochemical industries.

Valvekits spool kit service encompasses

design, stress calculations and

manufacture for valve sizes up to or in

excess of 900mm (36). All activities are

performed to ISO 9001 quality standards

and include full material certification when

required.

Heavy duty spoolkits for oil and gasindustry valves

Jordan electric modulatingactuators in the power andoil industries

SM6000 rotary actuators

deliver positional accuracy within

one tenth of 1% throughout a

standard stroke of 313 degrees.

Designed for precise damper

operation in power generation, steel

mill, paper making and oil refining

industries, the SM6000 provides up

to 36,540 Nm (26,000 ft lbs) of

torque at high speed for unrestricted,

continuous modulating duties in

exposed environments. An internal

digital amplifier is fitted for

commissioning and programming,

which is easily achieved by means of

an innovative keypad and

fluorescent display on a control

panel that is either attached to the

actuator or mounted separately.

SM6000s can be specified for

single or three phase power

operation, with manual override

fitted as standard. The actuator is

self locking in position on loss ofpower, whilst loss of control signal

can be programmed to either

stay-put or move to pre-set failsafe

position modes.

to only 0.9mA if a control signal is

not received after two seconds.

Modulating control can be

communicated by means of a

4 to 20mA analogue signal or a

HART digital multi-drop diagnostic

circuit. The compact, corrosion

resistant design further contributes

to a low maintenance service lifethat has provided up to 15%

savings in operating costs

compared to traditional choke valve

actuation whilst improving

production output by 12% through

the ability to quickly and

economically alter operating

parameters.

Find out more about Jordan: www.jordancontrols.com

Jordan 1000 series actuators have

a proven record of more than four

years of reliable choke valve

operation in over 3000 continuous

gas lift well applications. Available

with linear or multi-turn outputs, the

1000 series operates with a low

current draw from a 24V dc power

supply, making it particularly suitablefor battery operated applications.

This not only minimises capital plant

costs in remote or offshore locations

but also introduces the possibility of

using solar panels to maintain

battery power sources. To further

preserve power a sleeper circuit

version reduces power consumption

Gas lift automation

digital or analogue controlRotork Valvekits has built a

reputation in the UK for next dayand express deliveries of custommade stainless steel valvemounting kits. This service is nowavailable on the Europeanmainland.

Rotork Valvekits has built a

reputation in the UK for next dayand express deliveries of custommade stainless steel valvemounting kits. This service is nowavailable on the Europeanmainland.

Valvekits has launched a complete

range of high quality fabricated

steel handwheels, available in

sizes from 150mm (6) to 1200mm

(48). Applications include

gearboxes, valves, shutters,

chainwheels and

manual extensions.

Contact Rotork Valvekits: hmutters@valvekits.co.ukContact Rotork Valvekits: hmutters@valvekits.co.ukContact Rotork Valvekits: hmutters@valvekits.co.uk

SM6000 the new name

for high performance

SM6000 the new name

for high performance

SM6000 the new name

for high performance

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http://www.rotork.com

UK head office

Rotork Controls Limited

tel Bath 01225 733200

fax 01225 333467

mail@rotork.co.uk

USA head office

Rotork Controls Inc

tel Rochester (585) 328 1550

fax (585) 328 5848

info@rotork.com

Rotalk is published and printed

in the UK.

Produced by FTPublicity

tel 01225 865399

The fast-track contract, achievedin ten weeks by Rotork Fluid

Systems centre of excellence at

Leeds, involved fitting and

testing Rotork RP and GP

actuators with ANSI Class 900

metal seated ball valves

manufactured by International

Ball Valves Ltd. The completed

valve packages are being

installed on Shells Anasuria

Rotork awarded critical duty

contract by Shell Expro

Like its big brothers, the CP

range features a sturdy, modular

design. Internal support bearings

in the fully sealed centre body

maintain piston alignment to

ensure a long service life, whilst

the nitrided yoke provides

enhanced bearing surface

performance. Cylinders are

electroless nickel plated on

internal surfaces to prolong piston

seal life.

The dual mounting capability

facilitates open or close failsafeoperation, with control mounting

pads on both body faces to

assist with the packaging of

RotorkFluid System

Rotork Fluid System has been selected by Shell Expro

at Aberdeen to supply failsafe pneumatic valve

actuators for an emergency shutdown critical duty

offshore application.

Left:

Some of the completed Rotork Fluid

System actuated valve packages

destined for the Shell AnasuriaProject

CP range the newname for compactpneumatic actuators

Project in the North Sea FPSOCentral Field.

Rotorks UK Fluid System

Divisional Director Mark

Thomas describes the order

as a significant step; our

ability to design, fabricate

and deliver in such a short

timescale was paramount to

securing the order.

Rotork Fluid System has introduced a new range of small quarter-turn

pneumatic actuators, enabling the proven benefits of Rotorks larger,

heavy duty scotch yoke actuator designs to be applied to the operation

of small to medium sized valves.

control equipment. NAMUR

standard drive shaft dimensions

are compatible with most valve

designs, simplifying the

adaptation requirements.

Designed for a maximum

pneumatic operating pressure of

12 Barg, CP actuators provide an

end of spring torque range of

28Nm to 1456Nm. The modular

design enables actuator

components to be swiftly

assembled from stocks that will

be held at Rotork Fluid Systemcentres of excellence around the

world.

www.rotork.comFor further information, ask for publication F1100E.

PED compliant

Suitable for SIL applications

NAMUR standard interface facilitates accessory mountingand reduces costs

Versatile dual valve and accessory mounting faces

Modular design provides for easy and efficient stockability

Outboard mounted pneumatic cylinder for serviceability

Electroless nickel-plated cylinders

Integral manual override

Optional materials:stainless steel cylindercast steel body

GOSTRotork Fluid System has also

successfully obtained GOST

approval, enabling the product

range to be used in Russia.

Approvals news:

PEDRotork Fluid System actuators

are now approved in

accordance with the European

Pressure Equipment Directive

(PED) when applicable,

following validation conducted

by Bureau Veritas. Where

required, all pressure vessels

now carry the CE mark.

New Italiansales officeThe sales office for Rotork Fluid

System in Italy has moved to newpremises at the following address:

Via Scapuzzi 44/D

Fiorenzuola dArda

Piacenza 29017

Telephone +39 0523 243311

Fax +39 0523 243310

Email: sales@fluidsystem.it